Spliced shielded wire cable

ABSTRACT

A wire harness having at least wire harness assembly having a splice of at least three shielded wire cables is presented. The assembly includes a flexible insulation layer wrapped about the joined core conductors of the three cables, a flexible conductive layer wrapped about the shield conductors of the cables, and a section of dual wall heat shrink tubing enclosing the flexible conductive layer and portions of the insulative jackets of the cables. The flexible conductive layer does not include any solder.

CROSS-REFERENCE TO RELATED APPLICATION

This application is a divisional application of U.S. patent applicationSer. No. 14/274,857, filed May 12, 2014, the entire disclosure of whichis hereby incorporated herein by reference.

TECHNICAL FIELD OF THE INVENTION

The invention generally relates to a method for splicing shielded wirecables and the spliced wire cables produced by this method.

BACKGROUND OF THE INVENTION

Shielded wire cables typically include an insulated core conductor and aseparate insulated shield conductor surrounding the core conductorinsulation. The shield conductor may consist of a braided wire mesh,metal foil, or metalized film. The cables typically have a secondinsulation layer covering the shield conductor. Shielded wire cableshave been long used for communications systems, such as in cabletelevision transmission lines. Shielded wire cables are also finding usein high voltage applications in electric and hybrid electric vehicles.When shielded wire cables are spliced together, there is usually a needto electrically connect the shield conductors of the spliced cables aswell as the core conductor, in order to maintain electrical continuityof the shield conductors. Interconnecting the shield conductors may becomplicated because the shield conductors must be cut back from thespliced ends of the cable in order to join the core conductors.Interconnecting the shield conductors may be further complicated in aone-to-many splicing configuration, sometimes referred to as a Y-splice.

A prior art method splicing shielded wire cables involved joining thecenter conductors of the cables using a crimping connection, coveringthe crimped joint with an insulator, such as heat shrinkable tubing andthen covering the exposed shield conductors and insulated joint with aflux coated solder impregnated conductive sleeve within a section ofheat shrinkable tubing. Such a solder impregnated conductive sleevewithin a section of heat shrinkable tubing is available from TEConnectivity Corporation of Menlo Park Calif. (formerly TycoCorporation) under the brand name SolderShield.

The subject matter discussed in the background section should not beassumed to be prior art merely as a result of its mention in thebackground section. Similarly, a problem mentioned in the backgroundsection or associated with the subject matter of the background sectionshould not be assumed to have been previously recognized in the priorart. The subject matter in the background section merely representsdifferent approaches, which in and of themselves may also be inventions.

BRIEF SUMMARY OF THE INVENTION

In accordance with a first embodiment and second embodiment of thisinvention, a wire harness assembly is provided. The wire harnessassembly includes a first shielded wire cable having a first coreconductor at least partially axially surrounded by a first shieldconductor which is at least partially axially surrounded by a firstinsulative jacket, a second shielded wire cable having a second coreconductor at least partially axially surrounded by a second shieldconductor which is at least partially axially surrounded by a secondinsulative jacket, and a third shielded wire cable having a third coreconductor at least partially axially surrounded by a third shieldconductor which is at least partially axially surrounded by a thirdinsulative jacket, wherein the first, second and third core conductorsform a directly joined portion and the first, second, and third shieldconductors are physically separated one from another. The wire harnessassembly also includes a conductive sleeve defining a longitudinal axisand a first axial passage enclosing a portion of the first, second, andthird shield conductors and defining a first contact attached to thefirst shield conductor, a second contact attached to the second shieldconductor, and a third contact attached to the third shield conductor,wherein the first, second, and third insulative jackets are separatedone from another and wherein enclosed portions of the of the first,second, and third shield conductors are substantially parallel to thelongitudinal axis. The wire cable assembly further includes an outerinsulator sealably engaging the first, second, and third insulativejackets and enclosing the conductive sleeve.

The wire harness assembly may include an inner insulator disposed withinthe first axial passage and defining a second axial passage enclosingthe joined portion of the first, second, and third core conductors. Theinner insulator and the sleeve may have a generally elliptical crosssection. A portion of the second axial passage may be narrowed such thatonly a single shielded cable may be disposed within the portion of thesecond axial passage. The sleeve may define a crimping wing configuredto form the first contact and the sleeve may define a U-shaped slotconfigured to form the second and third contact. The first, second, andthird contact may each define a hole configured to allow the injectionof solder paste into the interior of the first, second, and thirdcontacts. The wire harness assembly may further include a plurality offerrules attached to each of the first, second, and third shieldconductors, wherein the first, second and third contacts are attached toat least one of the plurality of ferrules. At least one ferrule in theplurality of ferrules may be formed of solder.

The first, second, and third contact may be attached to the first,second, and third outer conductor respectively by a plurality offerrules. The sleeve may include a first sleeve portion configured to bejoined to a second sleeve portion and the inner insulator may include afirst inner insulator portion configured to be joined to a second innerinsulator portion.

A method of splicing shielded wire cables in accordance with the firstor second embodiment of this invention is provided. The method includesthe steps of providing a first shielded wire cable having a first coreconductor at least partially axially surrounded by a first shieldconductor which is at least partially axially surrounded by a firstinsulative jacket, providing a second shielded wire cable having asecond core conductor at least partially axially surrounded by a secondshield conductor which is at least partially axially surrounded by asecond insulative jacket, providing a third shielded wire cable having athird core conductor at least partially axially surrounded by a thirdshield conductor which is at least partially axially surrounded by athird insulative jacket, providing a shield defining a longitudinalaxis, a first axial passage, and a first, second, and third contact,said shield formed of a conductive material, and providing an innerinsulator defining a second axial passage, said inner insulator formedof a dielectric material. The method also includes the steps of joiningthe first core conductor to the second core conductor and the third coreconductor, disposing the joined first, second, and third core conductorswithin the second axial passage, disposing the inner insulator and thefirst, second, and third shield conductors within the first axialpassage, wherein the portions of the of the first, second, and thirdshield conductors disposed within the inner insulator are substantiallyparallel to the longitudinal axis, and separating the first, second, andthird insulative jackets one from another. The method further includesthe steps of attaching the first contact to the first shield conductor,the second contact to the second shield conductor, and the third contactto the third shield conductor, thereby providing a conductive pathbetween the first, second, and third shield conductors, providing anouter insulator formed of a nonconductive material, disposing the shieldwithin the outer insulator, and sealably engaging the outer insulator tothe first, second, and third insulative jackets, thereby enclosing theshield within the outer insulator. The joined first, second, and thirdcore conductors may be slideably disposed within the second axialpassage and the first, second, and third shield conductors may beslidably disposed within the first axial passage.

Where the first, second, and third contact each define a hole, themethod may include the steps of injecting solder paste into the interiorof the first, second, and third contacts through the holes definedtherein and heating the solder paste until it reflows, thereby solderingthe first, second, and third contacts to the first, second, and thirdshield conductors respectively. The method may optionally include thesteps of providing a first, second, and third ferrule; attaching thefirst, second, and third ferrule to the first, second, and third shieldconductors respectively, crimping the first, second, and third ferruleto the first, second, and third contacts respectively, thereby attachingthe first, second, and third contacts to the first, second, and thirdshield conductors respectively.

Where the sleeve includes a first sleeve portion and a second sleeveportion, the method may additionally include the step of joining thefirst sleeve portion to the second sleeve portion, thereby disposing thejoined first, second, and third core conductors within the second axialpassage.

Where the inner insulator includes a first inner insulator portion and asecond inner insulator portion, the method may further include the stepof joining the first inner insulator portion to the second innerinsulator portion, thereby disposing the inner insulator and the first,second, and third shield conductors within the first axial passage.

Where the outer insulator further includes an end cap configured tosealably engage the outer insulator and at least one shielded wirecable, the method may also include the steps of sealably engaging theend cap with the at least one shielded wire cable and sealably engagingthe end cap with the outer insulator, thereby enclosing the shieldwithin the outer insulator.

Another method of splicing shielded wire cables in accordance with athird embodiment of this invention is provided. The method includes thesteps of providing a first, second, and third shielded wire cable eachhaving a core conductor at least partially axially surrounded by ashield conductor which is at least partially axially surrounded by aninsulative jacket, providing a flexible insulation layer, providing aflexible conductive layer, and providing a section of dual wall heatshrink tubing. The method also includes the steps of wrapping a firstportion of the flexible insulation layer about the joined first, second,and third core conductors, wrapping the flexible conductive layer aboutthe first, second, and third shield conductors, and disposing theflexible conductive layer and portions of the first, second, and thirdinsulative jacket within the section of dual wall heat shrink tubing.

This method may further include the steps of wrapping a second portionof the flexible insulative layer about the first portion of the flexibleinsulative layer, wrapping a third portion of the flexible insulativelayer about a portion of the insulative layer of the first shielded wirecable and a first portion of the flexible conductive layer, wrapping afourth portion of the flexible insulative layer about a portion of theinsulative layer of the second and third shielded wire cables and asecond portion of the flexible conductive layer, providing a first andsecond ferrule, wrapping the first ferrule about the insulative layer ofthe second shielded wire cable, and wrapping the second ferrule aboutthe insulative layer of the third shielded wire cable adjacent the firstferrule. The first and second ferrule may be disposed within the sectionof dual wall heat shrink tubing.

The first portion of the flexible insulative layer may be formed of acloth tape. The second, third, and fourth portions of the flexibleinsulative layers may be formed of a section of heat shrink tubing. Thefourth portion of the flexible insulative layer may have a largerdiameter than the third portion of the flexible insulative layer priorto shrinking. The first and second ferrules may also be formed of asection of heat shrink tubing.

In accordance with the third embodiment of this invention, a wireharness assembly having a splice of at least three shielded wire cablesis provided. The wiring harness includes a first shielded wire cablehaving a first core conductor at least partially axially surrounded by afirst shield conductor which is at least partially axially surrounded bya first insulative jacket; a first, second, and third shielded wirecable each having a core conductor at least partially axially surroundedby a shield conductor which is at least partially axially surrounded byan insulative jacket, wherein the first core conductor is electricallyand mechanically coupled to the second core conductor and the third coreconductor. The wire harness assembly further includes a first flexibleinsulation layer wrapped about the joined first, second, and third coreconductors, a flexible conductive layer wrapped about the first, second,and third shield conductors, and a section of dual wall heat shrinktubing in which the third and fourth flexible insulative layers andportions of the first, second, and third insulative jacket are disposed.The flexible conductive layer does not include solder.

The wire harness assembly may further include a second flexibleinsulative layer wrapped about the first insulative layer, a thirdflexible insulative layer wrapped about a portion of the insulativelayer of the first shielded wire cable and a first portion of theflexible conductive layer, a fourth flexible insulative layer wrappedabout a portion of the insulative layer of the second and third shieldedwire cables and a second portion of the flexible conductive layer, afirst ferrule wrapped about the insulative layer of the second shieldedwire cable, and a second ferrule wrapped about the insulative layer ofthe third shielded wire cable and adjacent the first ferrule, whereinthe first and second ferrules are also disposed within the section ofdual wall heat shrink tubing.

The first insulative layer may be formed of a cloth tape and theflexible conductive layer is formed of braided strands.

Further features and advantages of the invention will appear moreclearly on a reading of the following detailed description of thepreferred embodiment of the invention, which is given by way ofnon-limiting example only and with reference to the accompanyingdrawings.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING

The present invention will now be described, by way of example withreference to the accompanying drawings, in which:

FIG. 1 is a schematic diagram of a prior art electrical load connectionscheme;

FIG. 2 is a schematic diagram of an electrical load connection scheme inaccordance with a first and second embodiment;

FIG. 3 is an illustration of a wire harness assembly having a coreconductor splice connection in accordance with the first embodiment;

FIG. 4 is a perspective view of a wire harness assembly having an innerinsulator pre-loaded on a shielded wire cable in accordance with thefirst embodiment;

FIG. 5 is a perspective view of a wire harness assembly having the innerinsulator enclosing the core conductor splice connection in accordancewith the first embodiment;

FIG. 6 is semi-transparent perspective view of the inner insulator ofthe wire harness assembly of FIG. 5 enclosing the core conductor spliceconnection in accordance with the first embodiment;

FIG. 7 is a cut-away view of the inner insulator of the wire harnessassembly of FIG. 6 enclosing the core conductor splice connection inaccordance with the first embodiment;

FIG. 8 is a perspective view of a wire harness assembly having a shieldpre-loaded on the shielded wire cable in accordance with the firstembodiment;

FIG. 9 is a perspective view of the shield the wire harness assembly ofFIG. 8 enclosing the inner insulator in accordance with the firstembodiment;

FIG. 10 is a cut-away view of the shield of the wire harness assembly ofFIG. 9 enclosing the inner insulator in accordance with the firstembodiment;

FIG. 11A is a perspective view of crimping a contact of the wire harnessassembly of FIG. 10 to a shield conductor in accordance with the firstembodiment;

FIG. 11B is a close up top view of the crimped contact of the wireharness assembly of FIG. 11A in accordance with the first embodiment;

FIG. 12 is a top view of an outer insulator enclosing the shield of thewire harness assembly of FIG. 10 in accordance with the firstembodiment;

FIG. 13 is a top view of the wire harness assembly in accordance withthe first embodiment;

FIG. 14 is an exploded perspective view of a wiring harness assembly inaccordance with a second embodiment;

FIG. 15 is perspective view of an inner insulator of the wiring harnessassembly of FIG. 14 in accordance with the second embodiment;

FIG. 16 is a perspective view of an assembly of the inner insulators ofthe wiring harness assembly of FIG. 14 in accordance with the secondembodiment;

FIG. 17 is a perspective view of an assembly of inner insulators of thewiring harness assembly of FIG. 14 disposed within a portion of a sleevein accordance with the second embodiment;

FIG. 18 is a perspective view of an assembly of inner insulators of thewiring harness assembly of FIG. 14 enclosed within a sleeve inaccordance with the second embodiment;

FIG. 19 is a perspective view of an assembly of fastening devices tocontacts defined by the sleeve of the wiring harness assembly of FIG. 14in accordance with the second embodiment;

FIG. 20 is perspective view of a sleeve of the wiring harness assemblyof FIG. 14 in accordance with the second embodiment;

FIG. 21 is a perspective view of an assembly of a shield assembly withinan outer insulator of the wiring harness assembly of FIG. 14 inaccordance with the second embodiment;

FIG. 22 is a perspective view of an assembly of end caps to shieldedwire cables of the wiring harness assembly of FIG. 14 in accordance withthe second embodiment;

FIG. 23 is a perspective view of an assembly of the end caps to theouter insulator of the wiring harness assembly of FIG. 14 in accordancewith the second embodiment;

FIG. 24 is a perspective view of the outer insulator of the wiringharness assembly connected to another outer insulator of another wiringharness assembly in accordance with the second embodiment; and

FIG. 25A is a side view of two wiring harness assemblies disposed withina wiring conduit in accordance with the second embodiment;

FIG. 25B is an end view of two wiring harness assemblies disposed withina wiring conduit in accordance with the second embodiment;

FIG. 26A is a perspective view of the shield the wire harness assemblyof FIG. 9 having four shielded wire cables in accordance with the firstembodiment;

FIG. 26B is a cut-away view of the shield the wire harness assembly ofFIG. 26A in accordance with the first embodiment;

FIG. 26C is a cross section view of the shield the wire harness assemblyof FIG. 26A in accordance with the first embodiment;

FIG. 27A is a flow chart of a method of splicing shielded wire cables inaccordance with the first and second embodiment;

FIG. 27B is a continuation of the flow chart of FIG. 27A in accordancewith the first and second embodiment;

FIG. 28 is a flow chart of a method of splicing shielded wire cables inaccordance with a third embodiment;

FIG. 29 is a top view of a wire harness assembly having a first flexibleinsulative layer wrapped about the spliced shielded wire cable of FIG. 3in accordance with the third embodiment;

FIG. 30 is a top view of a wire harness assembly having a secondflexible insulative layer insulator wrapped about the first flexibleinsulative layer of FIG. 29 in accordance with the third embodiment;

FIG. 31 is a top view of a wire harness assembly having a first andsecond ferrule insulator wrapped about the outer insulative jackets oftwo of the shielded wire cables of FIG. 30 in accordance with the thirdembodiment;

FIG. 32 is a top view of a wire harness assembly having a flexibleconductive layer wrapped about the exposed shield conductors of theshielded wire cables of FIG. 31 in accordance with the third embodiment;

FIG. 33 is a top view of a wire harness assembly having a third flexibleinsulation layer wrapped about a portion of the flexible conductivelayer of FIG. 32 in accordance with the third embodiment;

FIG. 34 is a top view of a wire harness assembly having a fourthflexible insulation layer wrapped about a portion of the flexibleconductive layer and the third flexible insulation layer of FIG. 33 inaccordance with the third embodiment; and

FIG. 35 is a top view of a wire harness assembly having a section ofdual wall heat shrink tubing wrapped about the third and fourth flexibleinsulation layer and the first and second ferrules of FIG. 34 inaccordance with the third embodiment.

FIG. 36 is a cross section view of the wire harness assembly of FIG. 35in accordance with the third embodiment.

DETAILED DESCRIPTION OF THE INVENTION

Described herein are devices and a methods for splicing two or moreshielded wire cables. The devices and methods may be used to spliceshielded wire cables with a single core conductor or multiple coreconnectors. The devices and methods described herein may be used tosplice together two shield wire cables, for example to repair a cutcable. The devices and methods described herein may also be used tosplice one shielded wire cable to two or more shielded wire cables toform a Y-splice. The devices and methods described herein may be usedfor splicing a variety of shielded wire cables types, for exampleshielded wire cables for communication transmissions, such as RG-59cable, or high voltage shielded wire cables designed for electrical orhybrid electrical vehicles.

FIG. 1 illustrates a prior art scheme for connecting electrical loads 1to a battery pack 2, such as in an electric vehicle. Each electricalload 1 requires a pair of high voltage shielded wire cables (positive 3and negative 4 polarity) running from the battery pack 2 to theelectrical load 1 and a separate fuse 5 protecting each of the circuits.

FIG. 2 illustrates a non-limiting example of a scheme for connectingelectrical loads 11 to a battery pack 12, such as in an electric vehicleby splicing together a pair of positive cables 13 and a pair of negativecables 14 using the devices and methods presented herein. The inventorsdiscovered that several circuits may be combined and share a single fuse15, for example because the electrical loads 11 are not usedconcurrently. The electrical loads 11 may also be connected to acontroller 22 that enables the electrical loads 11 to operate one at atime so that they are not used concurrently or the controller maymonitor the current used by each of the electrical loads 11 and controleach of the electrical loads 11 so that the total current used by theelectrical loads 11 is less than the current rating required to blow, oropen, the fuse 15. The inventors realized that a pair of high voltageshielded wire cables 13, 14 to these electrical loads 1 could be splicedtogether as shown in FIG. 2 with a shielded cable splice device 20,hereinafter device 20, that connects the core conductors 17 of theshielded wire cables 13, 14 while maintaining isolation and continuityof the shield conductors (not shown) of the shielded wire cables 13, 14,thereby reducing the length of shielded wire cable 13, 14 required tointerconnect the electrical loads 11 to the battery pack 12, thusreducing shielded wire cable 13, 14 cost, weight, packaging space, andwire routing complexity for the wiring harness. Because multipleelectrical loads 11 can share a single fuse 15, The number of fusedcircuits in the battery pack 12 could also be reduced; further reducingcost and complexity of the battery pack 12 by reducing the number offuses 15 and cable connectors 16 compared with the prior art scheme ofFIG. 1.

FIG. 3 illustrates a non-limiting example of three high voltage shieldedwire cables a first shielded cable 110, a second shielded cable 112, anda third shielded cable 114 that have been spliced together. A coreconductor 116, 118, 120 of each of the shielded cables 110, 112, 114 hasbeen joined by a sonic welding process to form a connection 122.Portions of the outer insulation layers 124, 126, 128, shield conductors130, 132, 134, and inner insulation layers 136, 138, 140 have beenremoved from the core conductors 116, 118, 120 prior forming theconnection 122. Alternatively, other processes well known to thoseskilled in the art, such as soldering or crimping the conductors withina conductive sleeve may be used to form the connection 122. Anadditional portion of each of the shield conductors 130, 132, 134 may beremoved or cut way to provide adequate voltage creepage distance 142 toprevent a leakage current between the core conductors 116, 118, 120 andthe shield conductors 130, 132, 134, thereby exposing the innerinsulation layers 136, 138, 140 of the shielded cables 110, 112, 114.Additionally, conductive ferrules 144, 146, 148 may be mechanically andelectrically attached to the shield conductors 130, 132, 134 to providea more durable electrical connection to the shield conductors 130, 132,134. The ferrules may be a closed or barrel-type ferrule that isattached to the shield conductors by crimping or soldering prior toforming the connection 122 or the ferrules may be an open or clip-typeferrule that can be attached to the shield conductors by crimping afterforming the connection 122. The ferrules may be formed of a soldermaterial that is heated, for example by induction heating, until theferrules reflow and join the contacts to the shield conductors. Theferrules may comprise an inner ferrule that is disposed between theshield conductor and the inner insulation layer and an outer ferrulethat is disposed over the shield conductor. Materials and methods usedto attach the conductive ferrules 144, 146, 148 to the shield conductors130, 132, 134 are well known to those skilled in the art.

FIGS. 4 through 15 illustrate a non-limiting example of a process offorming a shielded cable assembly 150 having both the core conductors116, 118, 120 and the shield conductors 130, 132, 134 of three shieldedwire cables 110, 112, 114 spliced together according to a firstembodiment. The embodiment illustrated here is configured to splicethree shielded wire cables 110, 112, 114 together in a Y-spliceconfiguration. However, alternative embodiments may be envisioned thatare configured to splice just two shielded wire cables or splice morethan three shielded wire cables.

As illustrated in FIG. 4, the wire cable assembly 150 includes an innerinsulator 152 formed of dielectric material. The dielectric material maybe a polymer material, such as glass-filled polyamide (commonly known bythe trade name NYLON) or polybutylene terephthalate (PBT). The innerinsulator 152 may be formed using an injection molding process or otherplastic forming processes well known to those skilled in the art. Theinner insulator 152 is designed to enclose the exposed portion of theconnection 122 and a portion of the exposed inner insulation layers 136,138, 140 of the shielded cables 110, 112, 114.

The inner insulator 152 defines an axial passage 154, hereafter referredto as a channel 154 that is designed to accommodate the connection 122and the joined shielded wire cables 110, 112, 114. As shown in FIGS. 5and 6, the inner insulator 152 may then be slid over the single shieldedcable 110 along the longitudinal axis A in the direction 156 over theconnection 122, leaving the shield conductors 130, 132, 134 exposed.

As shown in FIG. 7, the channel 154 of the inner insulator 152 maydefine shoulders 158 to provide a positive stop against the two joinedcore conductors 118, 120 and ensure proper positioning of the innerinsulator 152 relative to the connection 122 and the exposed shieldconductors 130, 132, 134. The inner insulator 152 may be designed with asymmetrical shape so that the shoulders 158 contact the two joined coreconductors 118, 120 regardless of the orientation of the inner insulator152 when the inner insulator 152 is placed on the single shielded wirecable 110.

As shown in FIG. 8, the wire cable assembly 150 further includes asleeve 160 formed of conductive material that defines an axial passage161, hereafter referred to as a cavity 161 along a longitudinal axis A.The conductive material used to form the sleeve 160 is preferably acopper alloy, such as 425 brass and may be tin coated for corrosionresistance. As shown in FIG. 9, the sleeve 160 may be slid along thelongitudinal axis A in the direction 156 over the inner insulator 152,disposing the inner insulator within the cavity 161. The sleeve 160defines contacts 162, 164, 166 that are designed to be crimped intomechanical and electrical contact with the shield conductors 130, 132,134. The sleeve 160 may define a generally elliptical cross section. Asused herein, generally elliptical cross section means that thecircumferential shape of the sleeve varies by no more than ±10% fromthat of an elliptical cross section.

As shown in FIG. 10, the sleeve 160 may define lock features 168 thathold the sleeve 160 in proper position over the inner insulator 152. Thelock features 168 may define a pair of ramp structures 170 wherein oneof the ramp structures 170 is designed to deflect as the sleeve 160slides along the longitudinal axis A over the lock in the direction 156and then snap back into place, thereby capturing the inner insulator 152between the lock features 168. Alternatively, the sleeve may be slidalong the longitudinal axis in the direction opposite of direction 156.The sleeve 160 may be designed with a symmetrical shape so that the lockfeatures 168 secure the sleeve 160 to the inner insulator 152 regardlessof the orientation when the sleeve 160 is placed on the single shieldedwire cable 110. Other locking features well known to those skilled inthe art may alternately be utilized to secure the sleeve 160 in placeover the inner insulator 152. The shoulders 158 of the inner insulator152 and the lock features 168 of the sleeve 160 cooperate to locate theexposed shield conductors 130, 132, 134 or ferrules relative to thecontacts 162, 164, 166. This provides the benefit of more consistentconnections between the contacts and the shield conductors in themanufacturing process.

As illustrated in FIG. 11, the contacts 162, 164, 166 are crimped to theshield conductors 130, 132, 134 or ferrules attached to the shieldconductors 130, 132, 134, by applying a mechanical force to provide amechanical and electrical connection between the sleeve 160 and theshield conductors 130, 132, 134 and provide electrical continuitybetween all of the shield conductors 130, 132, 134. According to theillustrated example, the sleeve defines a plurality of U-shaped slots172 forming bands 174, 176, 178, 180 that are configured to deform whencrimped to secure the sleeve to the shield conductors or ferrules. Thebands 178, 180 forming contacts 164, 166 are crimped by applying forceto the central portion of the bands so that central portion of the bandspush the shielded wire cables 112, 114 apart and ensuring that theinsulating layers of shielded cables are separated, that is are not inphysical contact with one another. The portions of the first, second,and third shield conductors that are enclosed within the shield aresubstantially parallel to the longitudinal axis A. This provides asplice connection that is basically in-line which may be easier topackage within a location with limited space, such as within anautomobile. As used herein, substantially parallel means±10° ofabsolutely parallel. In an alternative embodiment, the sleeve 160 maydefine conventional crimping wings that connect to the shield conductorsor ferrules by wrapping about them and crimping. The crimping wings areconfigured to separate the insulating layers of the shielded cables. Inanother alternative embodiment, the contacts 162, 164, 166 may beelectrically and mechanically connected to the shield conductors 130,132, 134 by soldering or other processes well known to those skilled inthe art rather than crimping.

As illustrated in FIG. 12, an outer insulator 182 formed on a dielectricmaterial may be placed over the sleeve 160. The outer insulator 182 maybe formed of a thermoplastic heat shrink tubing. Suitable compositionsand sources of heat shrink tubing are well known to those skilled in theart. The outer insulator 182 may also be preloaded onto the blunt cutsingle shielded wire cable 110 prior to forming the connection 122. Theheat shrink tubing may then be heated using methods well known to thoseskilled in the art to sealably engage the outer insulation layers 124,126, 128 of at least one of the shielded wire cables 110, 112, 114 andenclose the sleeve 160 as shown in FIG. 13. As used herein, sealablyengaged means that the outer insulator 182 will resist contaminants,such as dust, dirt, or fluids, from entering between the outerinsulation layers 124, 126, 128 and the outer insulator 182. It does notmean that it provides a hermetic seal. Alternatively, the outerinsulator 182 may comprise or may consist of a conformal coating 184,such as a silicone-based material, applied over the sleeve 160 andshielded wire cables 110, 112, 114. The inventors have discovered thatseparation of the insulating layers of the shielded cables by the sleeveprovides the benefit of improved sealing between the outer insulator andthe shielded cables. Without subscribing to any particular theory ofoperation, the outer insulator or the sealant within the outer insulatoris able to contact the entire circumference of the outer insulationlayers 126, 128, thus avoiding any gaps or voids that may be created ifthe outer insulation layers 126, 128 were not separated or weretouching.

FIGS. 14 through 25B illustrate a non-limiting example of a process offorming a shielded cable assembly 150 having both the core conductors116, 118, 120 and the shield conductors 130, 132, 134 of three shieldedwire cables 110, 112, 114 spliced together according to a secondembodiment. The embodiment illustrated here is configured to splicethree shielded wire cables 110, 112, 114 together in a Y-spliceconfiguration. However, alternative embodiments may be envisioned thatare configured to splice just two shielded wire cables together orsplice more than three shielded wire cables together.

FIG. 14 illustrates another non-limiting example of a wire cableassembly 250. The reference numbers in this embodiment for identicalelements are the same as the previously described embodiment and thereference numbers of similar elements are 100 higher. The embodimentillustrated here is configured to splice three shielded wire cables 110,112, 114 together by connecting the core conductor 116, 118, 120 of eachof the shielded cables 110, 112, 114 to form a connection 122 as shownin FIG. 3 and described in paragraph 0042 supra. However, thisembodiment may be used to splice four shielded wire cables together andother embodiments may be envisioned that are configured to splice justtwo shielded wire cables together or splice more than four shielded wirecables together.

The shielded cable assembly 250 includes a first inner insulator 252Aformed of dielectric material and a second inner insulator 252B formedof a dielectric material. The dielectric material may be a polymermaterial, such as glass filed NYLON or PBT. The first inner insulator252A and the second inner insulator 252B may be formed of the samedielectric material or they may be formed of different dielectricmaterials. The first inner insulator 252A and the second inner insulator252B may be formed using an injection molding process or other plasticforming processes well known to those skilled in the art.

The first inner insulator 252A is designed to be joined to the secondinner insulator 252B and when the first inner insulator 252A and thesecond inner insulator 252B are joined, they enclose the connection 122and a portion of the exposed inner insulation layers 136, 138, 140 eachof the shielded wire cables 110, 112, 114.

As shown in FIG. 15, the first inner insulator 252A and the second innerinsulator 252B may define a pair of interconnected channels 254A, 254Bto secure the joined shielded wire cables 110, 112, 114 within the firstinner insulator 252A and the second inner insulator 252B. The firstinner insulator 252A and the second inner insulator 252B may alsoinclude a set of mating tapered posts 253 and indentations 255 in orderto facilitate alignment of the first inner insulator 252A and the secondinner insulator 252B when they are assembled around the shielded wirecables 110, 112, 114. The first inner insulator 252A and the secondinner insulator 252B may be designed with a hermaphroditic shape so thata single inner insulator 252 may be used for both the first innerinsulator 252A and the second inner insulator 252B. In the example shownhere, the joined inner insulator 252 may have an unused portion of thechannel 254A.

As illustrated in FIG. 18, the wire cable assembly 250 further includesa sleeve 260 formed of conductive material that defines a longitudinalaxis A. The conductive material used to form the sleeve 260 ispreferably a copper alloy, such as 425 brass and may be tin coated forcorrosion resistance. The sleeve 260 defines contacts 262, 264, 266 thatare designed to be in mechanical and electrical contact with the shieldconductors 130, 132, 134 of the shielded wire cables 110, 112, 114. Thecontacts 262, 264, 266 protrude from the sleeve 260 and form an arcuateshape configured to conform to the shield conductors 130, 132, 134 orferrules. As illustrated in FIG. 19, the contacts 262, 264, 266 may besecured to the shield conductors 130, 132, 134 by a separate fasteningdevice 284, such as a band or sleeve that may be crimped around thecontacts 262, 264, 266.

Alternatively, as shown in FIG. 20, the contacts 262, 264, 266 maydefine crimp wings 286 that have an arcuate shape prior to being crimpedaround the shield conductors 130, 132, 134 of each of the shielded wirecables 110, 112, 114. The contacts 262, 264, 266 are designed to contactthe shield conductors 130, 132, 134 to provide an electrical connectionbetween the shield conductors 130, 132, 134 of each of the shielded wirecables 110, 112, 114. The contacts 262, 264, 266 may also be designed tomechanically secure the shielded wire cables 110, 112, 114 to the sleeve260 and provide strain relief to the joined core conductor 116, 118, 120of the cables.

Returning to FIG. 18, the sleeve 260 is designed to enclose the firstinner insulator 252 and to define cable portals for each of the shieldedwire cables 110, 112, 114 to exit the sleeve 260. The sleeve 260 may bemade up of a first sleeve 260A that defines a set of contacts 262A,264A, 266A and a second sleeve 260B that defines another set of contacts262B, 264B, 266B. The first sleeve 260A is configured to enclose theinner insulator when mated with the second sleeve 260B. Features may beincluded in the joining surfaces of the first sleeve 260A and the secondsleeve 260B to reduce electrical resistance. Alternatively, the firstsleeve 260A and the second sleeve 260B may be secured together usingconductive threaded fasteners. The first sleeve 260A and the secondsleeve 260B may be designed with a hermaphroditic shape so that a singlepart may be used for both the first sleeve 260A and the second sleeve260B. In the example shown here, there may be an unused portal andcontact. The contacts 164, 166 push the shielded wire cables 112, 114apart and ensuring that the insulating layers of shielded cables areseparated, that is are not in physical contact with one another. Theportions of the first, second, and third shield conductors that areenclosed within the shield are substantially parallel to thelongitudinal axis. This provides a splice connection that is basicallyin-line which may be easier to package within a location with limitedspace, such as within an automobile.

As illustrated in FIG. 21, the wire cable assembly 250 may furtherinclude an outer insulator 282 formed of a nonconductive material anddefining a cavity 261 that is configured to partially enclose the sleeve260. The wire cable assembly 250 also includes a first end cap 288 thatis designed to sealably engage one of the shielded wire cables 110 andsealably engage the outer insulator 282 and a second end cap 290 that isdesigned to sealably engage the other two shielded wire cables 112, 114.The end caps and outer insulator 282 are designed to provideenvironmental protection to the spliced cables by keeping contaminantssuch as dust, dirt, water, and other fluids away from the joined coreconductors, joined inner insulator, and sleeve 260. The outer insulator282 and end caps may be formed of a polymer material, such as NYLON orPBT. The end caps may also include a sealing element 292 formed ofcompliant material, such as silicone rubber. The inventors havediscovered that separation of the insulating layers of the shieldedcables by the sleeve provides the benefit of improved sealing betweenthe sealing element 292 and the shielded cables. Without subscribing toany particular theory of operation, the sealing element 292 is able tocontact the entire circumference of the outer insulation layers 126,128, thus avoiding any gaps or voids that may be created if the outerinsulation layers 126, 128 were not separated or were touching.

As best illustrated in FIG. 23, the outer insulator 282 may include amale attachment feature 294 and a female attachment feature 296 that aredesigned to interconnect multiple outer insulators 282 as shown in FIG.24. These attachment features 294, 296 may simplify assembly of thewiring harnesses by maintaining a spatial relationship between the outerinsulators and provide a more robust wiring harness assembly becausethere is less likely to be vibrational contact between outer insulatorsthat may degrade the outer insulators 282 over time.

As illustrated in FIG. 25, multiple wire cable assemblies 250 may bepositioned in a staggered arrangement so that the wire cable assemblies250 may be enclosed with a wiring conduit 298. Staggering the wire cableassemblies 250 may offer the benefit of a smaller conduit and thereforerequire less packaging space for the resulting wiring harness.

Alternative embodiments may be envisioned by combining various featuresof the two embodiments illustrated in FIGS. 4-25. For example, the innerinsulator 152 and the sleeve 160 may comprise two separate portions,similar to the inner insulator 252 and sleeve 260. As another example,the sleeve 160 may define contacts that protrude from the sleeve thatare attached to the shield conductors or ferrules by a separatefastening device, such as a band or sleeve that may be crimped aroundthe contacts, similarly to the sleeve 260.

FIG. 26 illustrates a non-limiting method 300 of splicing shielded wirecables together. The method 300 includes the following steps.

STEP 310, PROVIDE A FIRST, SECOND, AND THIRD SHIELDED WIRE CABLE,includes providing a first shielded wire cable having a first coreconductor at least partially axially surrounded by a first shieldconductor which is at least partially axially surrounded by a firstinsulative jacket, providing a second shielded wire cable having asecond core conductor at least partially axially surrounded by a secondshield conductor which is at least partially axially surrounded by asecond insulative jacket, and providing a third shielded wire cablehaving a third core conductor at least partially axially surrounded by athird shield conductor which is at least partially axially surrounded bya third insulative jacket as shown in FIG. 3.

STEP 312, PROVIDE A SHIELD DEFINING A LONGITUDINAL AXIS, A FIRST AXIALPASSAGE, AND A FIRST, SECOND, AND THIRD CONTACT, includes providing ashield that defines a longitudinal axis, a first axial passage, a firstcontact, a second contact, and a third contact. The shield is formed ofa conductive material. The shield may be formed of one piece as shown inFIG. 9 or multiple pieces as shown in FIG. 14.

STEP 314, PROVIDE AN INNER INSULATOR DEFINING A SECOND AXIAL PASSAGEincludes providing an inner insulator defining a second axial passage.The inner insulator is formed of a dielectric material. The innerinsulator may be formed of one piece as shown in FIG. 5 or multiplepieces as shown in FIG. 14.

STEP 316, JOIN THE FIRST CENTER CONDUCTOR TO THE SECOND CENTER CONDUCTORAND THE THIRD CENTER CONDUCTOR, includes joining the first coreconductor to the second core conductor and to the third core conductorto form a mechanical and electrical connection between the coreconductors as shown in FIG. 3. The core conductors may be joined bysonic welding, soldering, or other methods of joining wires known tothose skilled in the art. The inner insulator and the ferrules may bepreloaded onto the shielded cables prior to joining the core conductors.

STEP 318, DISPOSE THE JOINED FIRST, SECOND, AND THIRD CORE CONDUCTORSWITHIN THE SECOND AXIAL PASSAGE, includes disposing the connectionincluding the joined first, second, and third core conductors within thesecond axial passage, or channel, of the inner insulator as shown inFIGS. 6 and 15. The joined first, second, and third core conductors maybe slideably disposed within the second axial passage as shown in FIG.6.

STEP 320, DISPOSE THE INNER INSULATOR AND THE FIRST, SECOND, AND THIRDSHIELD CONDUCTORS WITHIN THE FIRST AXIAL PASSAGE, includes disposing theinner insulator and the first, second, and third shield conductorswithin the first axial passage as shown in FIGS. 8-9 and 17-18. Theportions of the first, second, and third shield conductors that aredisposed within the inner insulator are substantially parallel to thelongitudinal axis. The inner insulator and the first, second, and thirdshield conductors may be slidably disposed within the first axialpassage as shown in FIGS. 8-9.

STEP 322, SEPARATE THE FIRST, SECOND, AND THIRD INSULATIVE JACKETS ONEFROM ANOTHER, includes separating the first, second, and thirdinsulative jackets one from another. This may be accomplished by theconnection of the first, second, and third shield conductors to thecontacts as shown in FIGS. 11 and 19.

STEP 324, ATTACH THE FIRST CONTACT TO THE FIRST SHIELD CONDUCTOR, THESECOND CONTACT TO THE SECOND SHIELD CONDUCTOR, AND THE THIRD CONTACT TOTHE THIRD SHIELD CONDUCTOR, includes attaching the first contact to thefirst shield conductor, the second contact to the second shieldconductor, and the third contact to the third shield conductor, therebyproviding a conductive path between the first, second, and third shieldconductors. The contacts may be attached to the shield conductors bycrimping wings, ferrules, soldering, or other methods known to thoseskilled in the art.

STEP 326, DISPOSE THE SHIELD WITHIN THE OUTER INSULATOR, includesdisposing the shield within the outer insulator as illustrated in FIGS.12 and 21-22.

STEP 328, SEALABLY ENGAGE THE OUTER INSULATOR TO THE FIRST, SECOND, ANDTHIRD INSULATIVE JACKETS, includes sealably engaging the outer insulatorto the first, second, and third insulative jackets, thereby enclosingthe shield within the outer insulator as illustrated in FIGS. 13 and22-23.

Method 300 may further include the following optional steps.

Prior to step 324, method 300 may include STEP 330, PROVIDE A FIRST,SECOND, AND THIRD FERRULE, which includes providing a first, second, andthird ferrule.

Following step 330, method 300 may include STEP 332, ATTACH THE FIRST,SECOND, AND THIRD FERRULE TO THE FIRST, SECOND, AND THIRD SHIELDCONDUCTORS RESPECTIVELY, which includes attaching the first, second, andthird ferrule to the first, second, and third shield conductorsrespectively.

Following step 330, method 300 may include STEP 334, CRIMP THE FIRST,SECOND, AND THIRD FERRULE TO THE FIRST, SECOND, AND THIRD CONTACTSRESPECTIVELY, which includes crimping the first, second, and thirdferrule to the first, second, and third contacts respectively, therebyattaching the first, second, and third contacts to the first, second,and third shield conductors respectively.

Prior to step 324, method 300 may include STEP 336, INJECT SOLDER PASTEINTO THE INTERIOR OF THE FIRST, SECOND, AND THIRD CONTACTS THROUGH THEHOLES DEFINED THEREIN, which includes injecting solder paste into theinterior of the first, second, and third contacts through holes definedby the first, second, and third contacts.

Following step 336, method 300 may include STEP 338, HEAT THE SOLDERPASTE UNTIL IT REFLOWS, which includes heating the solder paste until itreflows, thereby soldering the first, second, and third contacts to thefirst, second, and third shield conductors respectively.

Prior to step 320, method 300 may include STEP 340, JOIN A FIRST SLEEVEPORTION TO A SECOND SLEEVE PORTION, which includes joining the firstsleeve portion to the second sleeve portion, thereby disposing thejoined first, second, and third core conductors within the second axialpassage, wherein the sleeve includes a first sleeve portion and a secondsleeve portion.

Prior to step 318, method 300 may include STEP 342, JOIN A FIRST INNERINSULATOR PORTION TO A SECOND INNER INSULATOR PORTION, which includesjoining the first inner insulator portion to the second inner insulatorportion, thereby disposing the inner insulator and the first, second,and third shield conductors within the first axial passage, wherein theinner insulator includes a first inner insulator portion and a secondinner insulator portion.

Following step 326, method 300 may include STEP 344, SEALABLY ENGAGE ANEND CAP WITH AT LEAST ONE SHIELDED WIRE CABLE, which includes joiningsealably engaging the end cap with the at least one shielded wire cable,wherein the outer insulator further includes an end cap configured tosealably engage the outer insulator and at least one shielded wirecable.

Following step 344, method 300 may include STEP 346, SEALABLY ENGAGE THEEND CAP WITH THE OUTER INSULATOR, which includes engaging the end capwith the outer insulator, thereby enclosing the shield within the outerinsulator.

FIG. 28 illustrates another non-limiting method 400 of splicing shieldedwire cables together. The method 400 includes the following steps.

STEP 410, PROVIDE A FIRST, SECOND, AND THIRD SHIELDED WIRE CABLE,FLEXIBLE INSULATION LAYER, FLEXIBLE CONDUCTIVE LAYER, AND DUAL WALL HEATSHRINK TUBING, includes providing a first shielded wire cable 110 havinga first core conductor 116 at least partially axially surrounded by afirst inner insulation layer 136 which is at least partially axiallysurrounded by a first shield conductor 130 which is at least partiallyaxially surrounded by a first insulative jacket 124, providing a secondshielded wire cable 112 having a second core conductor 118 at leastpartially axially surrounded by a second inner insulation layer 138which is at least partially axially surrounded by a second shieldconductor 132 which is at least partially axially surrounded by a secondinsulative jacket 126, and providing a third shielded wire cable 116having a third core conductor 120 at least partially axially surroundedby a third inner insulation layer 140 which is at least partiallyaxially surrounded by a third shield conductor 134 which is at leastpartially axially surrounded by a third insulative jacket 128 as shownin FIG. 3. Step 410 also includes providing a flexible dielectricinsulation layer that may be formed of a flexible dielectric materialsuch as heat shrinkable plastic tubing made of a heat shrinkable plastic(e.g. polyolefin), cloth tape, or plastic tape. The flexible insulationlayer provided may be divided into sections of varied length and/or theflexible insulation layer may comprise various types of insulation suchas those described above and applied to various portions of the wireharness assembly. Step 410 further includes providing a flexibleconductive layer 518 that may be formed of a sleeve of braided wirestrands (e.g. tin plated copper wire strands), a metallic foil (e.g.copper or aluminum foil), or a metallized plastic film (e.g. aluminizedMYLAR film). The flexible conductive layer 518 is not impregnated withsolder and does not include solder.

STEP 412, REMOVE A POTION OF THE OUTER INSULATIVE JACKETS AND THE INNERINSULATION LAYERS FROM THE A FIRST, SECOND, AND THIRD SHIELDED WIRECABLE, includes removing a portion of the outer insulative jackets 124,126, 128 of the first, second, and third shield wire cables 112, 114,116 to expose the shield conductors 130, 132, 134 and removing a portionof the shield conductors 130, 132, 134 and the inner insulation layers136, 138, 140 to expose the core conductors 116, 118, 120 as shown inFIG. 3.

STEP 414, JOIN THE FIRST CORE CONDUCTOR TO THE SECOND CORE CONDUCTOR ANDTHE THIRD CORE CONDUCTOR, includes joining the first core conductor 116to the second core conductor 118 and to the third core conductor 120 toform a mechanical and electrical connection 122 between the coreconductors 116, 118, 120 as shown in FIG. 3. The core conductors 116,118, 120 may be joined by sonic welding, soldering, or other methods ofjoining wires known to those skilled in the art.

STEP 416, WRAP A FIRST FLEXIBLE INSULATION LAYER ABOUT THE EXPOSEDJOINED PORTION OF THE FIRST, SECOND, AND THIRD CORE CONDUCTORS, is anoptional step that includes wrapping a first flexible insulation layer510 about the joined portion 122 and the exposed portions of the coreconductors 116, 118, 120 so as to completely cover and enclose theexposed portions of the core conductors 116, 118, 120 while leaving theshield conductors 130, 132, 134 exposed as shown in FIG. 29. The firstflexible insulation layer 510 may be formed of a flexible dielectricmaterial such as heat shrinkable plastic tubing, cloth tape, or plastictape.

STEP 418, WRAP A SECOND FLEXIBLE INSULATION LAYER OVER THE FIRSTFLEXIBLE INSULATION LAYER, includes wrapping a second flexibleinsulation layer 512 over the first flexible insulation layer 510 whilestill leaving the shield conductors 130, 132, 134 exposed as shown inFIG. 30. The second flexible insulation layer 512 may be a section ofheat shrinkable plastic tubing that is placed over the first flexibleinsulation layer 510 and heated until it is in compressive contact withand encloses the first flexible insulation layer 510. The secondflexible insulation layer 512 may protect the first flexible insulationlayer 510 from moisture that could degrade the insulative properties ofthe first flexible insulation layer 510. The first flexible insulativelayer 510 may be an adhesive backed polyester tape to protect the secondflexible insulation layer from abrasion that could be caused by edges ofthe joined portion 122. The adhesive backing may simplify application ofthe cloth tape.

STEP 420, WRAP A FIRST AND SECOND FERRULE OVER THE OUTER INSULATIONLAYER OF THE SECOND AND THIRD SHIELDED WIRE CABLE, is an optional stepthat includes wrapping or placing first and second non-conductiveferrules 514, 516 over the outer insulation layers 126, 126 of thesecond and third shielded wire cables 112, 114 so that the first andsecond ferrules 514, 516 are proximate the exposed shield conductors132, 134 of the second and third shielded wire cables 112, 114 andadjacent to one another as shown in FIG. 31. The first and secondferrules 514, 516 may be formed of sections of heat shrinkable plastictubing that is placed over the second and third shielded wire cables112, 114 and heated until it is in compressive contact with the outerinsulation layers 126, 128 of the wire cables 112, 114. Alternatively,the first and second ferrules 514, 516 may be plastic rings placed overthe outer insulation layers 126, 128 of the second and third shieldedwire cables 112, 114. The first and second ferrules 514, 516 provide agap between the outer insulation layers 126, 126 of the second and thirdshielded wire cables 112, 114.

STEP 422, WRAP A FLEXIBLE CONDUCTIVE LAYER ABOUT THE EXPOSED SHIELDCONDUCTORS OF THE FIRST, SECOND, AND THIRD SHIELDED WIRE CABLE, includeswrapping a flexible conductive layer 518 over at least a portion of theexposed shield conductors 130, 132, 134 so that it is electrical contactwith all of the shield conductors 130, 132, 134 as shown in FIG. 32. Theflexible conductive layer 518 is preferably not in contact with theouter insulation layers 124, 126, 126 of the shielded wire cables 110,112, 114.

STEP 424, WRAP A THIRD FLEXIBLE INSULATION LAYER OVER A PORTION OF THEOUTER INSULATION LAYER OF THE FIRST SHIELDED WIRE CABLE AND A PORTION OFTHE FLEXIBLE CONDUCTIVE LAYER, is an optional step that includeswrapping a third flexible insulation layer 520 over a portion of theouter insulation layer 124 of the first shielded wire cable 112 that isproximate the exposed shield conductor 130 and over a portion of theflexible conductive layer 518 as shown in FIG. 33. STEP 422 may includeplacing the third flexible insulation layer 520 which is a section ofheat shrinkable plastic tubing over the outer insulation layer 124 ofthe first shield wire cable 112 and a portion of the flexible conductivelayer 518 and heating the heat shrinkable tubing until it is incompressive contact with and encloses the outer insulation layer 124 ofthe first shield wire cable 112 and a portion of the flexible conductivelayer 518. The shield conductor 130 is preferably completely enclosed bythe third flexible insulation layer 520.

STEP 426, WRAP A FOURTH FLEXIBLE INSULATION LAYER OVER A PORTION OF THEOUTER INSULATION LAYERS OF THE SECOND AND THIRD SHIELDED WIRE CABLES ANDA PORTION OF THE FLEXIBLE CONDUCTIVE LAYER, is an optional step thatincludes wrapping a fourth flexible insulation layer 522 over a portionof the outer insulation layers 126, 128 of the second and third shieldedwire cables 112, 114 that is proximate the exposed shield conductors132, 134 and over a portion of the flexible conductive layer 518, butnot over the first and second ferrules 514, 516 as shown in FIG. 34. Thefourth flexible insulation layer 522 may also be applied over a portionof the third flexible insulation layer 520 so that it overlaps the thirdflexible insulation layer 520. STEP 426 may include placing the fourthflexible insulation layer 522 which is a section of heat shrinkableplastic tubing over outer insulation layers 126, 128 of the second andthird shield wire cables 112, 114 and a portion of the flexibleconductive layer 518 and heating the heat shrinkable tubing until it isin compressive contact with and encloses the outer insulation layers126, 128 of the second and third shielded wire cable 112, 114 and aportion of the flexible conductive layer 518. The fourth flexibleinsulation layer 522 may also overlap a portion of the third flexibleinsulation layer 520 so that enclosure of the flexible conductive layer518 is assured. The section of heat shrink tubing used for the fourthflexible insulation layer 522 may have a larger diameter than thesection of heat shrink tubing used for the third flexible insulationlayer 520 in STEP 424 before it is heated.

STEP 428, WRAP A SECTION OF DUAL WALL HEAT SHRINK TUBING OVER THEFLEXIBLE CONDUCTIVE LAYER, includes wrapping a section of dual wall heatshrink tubing 524 over at least the flexible conductive layer 518 and aportion of the outer insulation layers 124, 126, 128 of the first,second, and third shielded wire cables 110, 112, 114 as shown in FIG.35. Dual wall heat shrink tubing 524 has an outer wall made of a heatshrinkable plastic such as polyolefin and an inner wall made of athermoplastic adhesive sealant 526. When the dual wall heat shrinktubing 524 is heated, the thermoplastic adhesive sealant 526 on theinner wall melts and adheres to the outer insulation layers 124, 126,128 as the outer wall shrinks to conform to the shielded cables 110,112, 114 and flexible conductive layer 518, thus forming a sealedshielded wire cable splice 528. A portion of the sealant 526 may extrudefrom the dual wall heat shrink tubing 524 as the outer wall shrinks. Thedual wall heat shrink tubing 524 may also be wrapped about the third andfourth flexible insulation layers 520, 522 as well as the first andsecond ferrules 514, 516, thus sealing these features within the dualwall heat shrink tubing 524 when heated. The first and second ferrules514, 516 provide a gap between the outer insulation layers 126, 128 ofthe second and third shielded wire cables 112, 114 that is filled by thesealant 526, blocking a possible leak path between the second and thirdshielded wire cables 112, 114.

While the method 400 shown in FIG. 28 and the sealed shielded wire cablesplice 528 shown in FIG. 35 include three shielded wire cables 110,112,114, other embodiments of the method 400 and the sealed shielded wirecable splice 528 may be envisioned having two shielded wire cables ormore than three shielded wire cables. Ferrules may be wrapped about theouter insulation layers of each shielded wire cable that is adjacent toanother shielded wire cable to provide a gap that is filled by theadhesive sealant 526 of the dual wall heat shrink tubing 524.

Accordingly, a shielded wire cable splice 528 and a method of splicing aplurality of shielded wire cables 400 are provided. The method 400provides a shielded wire cable splice 528 that is sealed fromenvironmental contamination. The shielded wire cable splice 528 and themethod 400 do not use solder to join the flexible conductive layer 518to the shield conductors 130, 132, 134. That allows the method 400 formthe shielded wire cable splice 528 by heating the flexible insulationlayers and the dual wall heat shrink tubing 524 to a lower temperaturethan would be required to reflow solder as required by prior art methodsdescribed in the Background of the Invention above. The lower heat usedprovides the advantage of reducing the likelihood of damage to theshielded wire cables 110, 112, 114 from the application of heat. Whenthe core conductors 116, 118, 120 of the shielded wire cables 110, 112,114 are joined using a sonic welding process, the use of solder iscompletely eliminated from the method 400 and the shielded wire cablesplice 528. The elimination of solder obviates the need forenvironmental precaution needed with the use of solder. Withoutsubscribing to any particular theory of operation, the compressivecontact of the third and fourth flexible insulation layers 520, 522and/or the dual wall heat shrink tubing 524 with the flexible conductivelayer 518 keeps the flexible conductive layer 518 in contact with theshield conductors 130, 132, 134, thereby providing a reliable electricalconnection between the flexible conductive layer 518 and the shieldconductors 130, 132, 134.

While this invention has been described in terms of the preferredembodiments thereof, it is not intended to be so limited, but ratheronly to the extent set forth in the claims that follow. Moreover, theuse of the terms first, second, etc. does not denote any order ofimportance, but rather the terms first, second, etc. are used todistinguish one element from another. Furthermore, the use of the termsa, an, etc. do not denote a limitation of quantity, but rather denotethe presence of at least one of the referenced items.

We claim:
 1. A wire harness assembly having a splice of at least threeshielded wire cables, comprising: a first shielded wire cable having afirst core conductor at least partially axially surrounded by a firstshield conductor which is at least partially axially surrounded by afirst insulative jacket; a second shielded wire cable having a secondcore conductor at least partially axially surrounded by a second shieldconductor which is at least partially axially surrounded by a secondinsulative jacket; a third shielded wire cable having a third coreconductor at least partially axially surrounded by a third shieldconductor which is at least partially axially surrounded by a thirdinsulative jacket, wherein the first core conductor is electrically andmechanically coupled to the second core conductor and the third coreconductor a first flexible insulation layer wrapped about the joinedfirst, second, and third core conductors; a flexible conductive layerwrapped about the first, second, and third shield conductors, whereinthe flexible conductive layer does not include solder; a section of dualwall heat shrink tubing in which the third and fourth flexibleinsulative layers and portions of the first, second, and thirdinsulative jacket are disposed.
 2. The wire harness assembly accordingto claim 1, wherein the flexible conductive layer is formed of braidedstrands.
 3. The wire harness assembly according to claim 1, furthercomprising a second flexible insulative layer wrapped about the firstinsulative layer.
 4. The wire harness assembly according to claim 3,further comprising: a third flexible insulative layer wrapped about aportion of the first insulative layer and a first portion of theflexible conductive layer; a fourth flexible insulative layer wrappedabout a portion of the second and third insulative layer and a secondportion of the flexible conductive layer.
 5. The wire harness assemblyaccording to claim 4, further comprising: a first ferrule wrapped aboutthe second insulative layer; and a second ferrule wrapped about thethird flexible insulative layer and adjacent the first ferrule, whereinthe first and second ferrules are also disposed within the section ofdual wall heat shrink tubing.
 6. The wire harness assembly according toclaim 5, wherein the first, second, third, and fourth flexibleinsulative layer and first and second ferrules are formed of a sectionof heat shrink tubing, the first insulative layer is formed of a clothtape, and the flexible conductive layer is formed of braided strands. 7.The wire harness assembly according to claim 6, wherein the fourthflexible insulative layer has a larger diameter than the third flexibleinsulative layer prior to shrinking.
 8. A wire harness assembly having asplice of at least three shielded wire cables, formed by a processcomprising the steps of: providing a first shielded wire cable having afirst core conductor at least partially axially surrounded by a firstshield conductor which is at least partially axially surrounded by afirst insulative jacket; providing a second shielded wire cable having asecond core conductor at least partially axially surrounded by a secondshield conductor which is at least partially axially surrounded by asecond insulative jacket; providing a third shielded wire cable having athird core conductor at least partially axially surrounded by a thirdshield conductor which is at least partially axially surrounded by athird insulative jacket; providing a flexible insulation layer;providing a flexible conductive layer, wherein the flexible conductivelayer does not include solder; providing a section of dual wall heatshrink tubing; wrapping a first portion of the flexible insulation layerabout the joined first, second, and third core conductors; wrapping asecond flexible insulative layer about the first insulative layer;wrapping the flexible conductive layer about the first, second, andthird shield conductors; wrapping a third flexible insulative layerabout a portion of the first insulative layer and a first portion of theflexible conductive layer; wrapping a fourth flexible insulative layerabout a portion of the second and third insulative layer and a secondportion of the flexible conductive layer; wrapping a first ferrule aboutthe second insulative layer; and wrapping a second ferrule about thethird insulative layer adjacent the first ferrule; and disposing theflexible conductive layer and portions of the first, second, and thirdinsulative jacket within the section of dual wall heat shrink tubing,wherein the first and second ferrules are disposed within the section ofdual wall heat shrink tubing.
 9. The wire harness assembly according toclaim 8, wherein the first insulative layer is formed of a cloth tape,the first, second, third, and fourth flexible insulative layer, andfirst and second ferrules are formed of a section of heat shrink tubing,wherein the flexible conductive layer is formed of braided strands.